Flexibly mounted disc brake rotor for pneumatic, electromotive, and/or hydraulic disc brakes

Abstract

A disc brake rotor includes at least one friction ring having a friction surface adapted for contact with a brake pad during braking, and an annular mounting portion by which the rotor is attachable to a hub. A connection permitting radial expansion and contraction of the friction ring relative to the mounting portion upon heating and cooling of the rotor is present between the friction ring and the mounting portion. This connection helps to resist cracking and subsequent failure of the rotor near its attachment to a hub.

1 . A rotor for a disc brake comprising:
 at least one friction ring including a friction surface adapted for contact with a brake pad during braking;   an annular mounting portion by which the rotor is attachable to a hub; and   a connection between the friction ring and the mounting portion permitting radial expansion and contraction of the friction ring relative to the mounting portion upon heating and cooling of the rotor.   
   
   
       2 . The rotor according to  claim 1 , wherein the mounting portion is a steel mounting portion, and wherein the connection includes circumferentially disposed steel tabs extending from the mounting portion with ends cast into the friction ring. 
   
   
       3 . The rotor according to  claim 1 , wherein the friction ring is one of a pair of interconnected friction rings. 
   
   
       4 . The rotor according to  claim 3 , wherein the mounting portion is a steel mounting portion, and wherein the connection includes a first set of circumferentially disposed tabs extending from the mounting portion with ends cast into one of the pair of friction rings and a second set of circumferentially disposed tabs extending from the mounting portion with ends cast into the other of the pair of friction rings. 
   
   
       5 . The rotor according to  claim 2 , wherein each tab has an “S” or a “Z” shaped cross section. 
   
   
       6 . The rotor according to  claim 4 , wherein each tab has an “S” or a “Z” shaped cross section. 
   
   
       7 . The rotor according to  claim 1 , wherein the mounting portion includes stress-relieving notches defined therein. 
   
   
       8 . The rotor according to  claim 1 , wherein the mounting portion is split to facilitate said radial expansion and contraction. 
   
   
       9 . The rotor according to  claim 3 , wherein the connection includes elements interconnecting the friction rings as well as slots, formed in a steel mounting ring including said annular mounting portion, within which said elements are slidable. 
   
   
       10 . The rotor according to  claim 9 , wherein the mounting ring includes a bend further facilitating radial expansion and contraction of the friction rings. 
   
   
       11 . The rotor according to  claim 1 , wherein the friction ring, the mounting portion, and the connection are integrally formed of cast iron. 
   
   
       12 . The rotor according to  claim 11 , wherein the connection is defined by a deformable portion of the rotor having at least one recurved section. 
   
   
       13 . The rotor according to  claim 1 , wherein the friction ring is formed of cast iron and both the annular mounting portion and the connection are formed of steel. 
   
   
       14 . The rotor according to  claim 13 , wherein the connection is pre-stressed in a direction to reduce stress as the friction ring expands during heating. 
   
   
       15 . The rotor according to  claim 14 , wherein the connection is pre-stressed in a radially inward direction before the friction ring is cast. 
   
   
       16 . The rotor according to  claim 1 , wherein the connection includes a bend facilitating radial expansion and contraction of the friction rings. 
   
   
       17 . A wheel hub having a rotor for a disc brake mounted thereon, the rotor comprising:
 at least one friction ring including a friction surface adapted for contact with a brake pad during braking;   an annular mounting portion by which the rotor is attachable to a hub; and   a connection between the friction ring and the mounting portion permitting radial expansion and contraction of the friction ring relative to the mounting portion upon heating and cooling of the rotor.   
   
   
       18 . The wheel hub according to  claim 17 , wherein the mounting portion is a steel mounting portion, and wherein the connection includes circumferentially disposed steel tabs extending from the mounting portion with ends cast into the friction ring. 
   
   
       19 . The wheel hub according to  claim 17 , wherein the friction ring is one of a pair of interconnected friction rings. 
   
   
       20 . The wheel hub according to  claim 19 , wherein the mounting portion is a steel mounting portion, and wherein the connection includes a first set of circumferentially disposed tabs extending from the mounting portion with ends cast into one of the pair of friction rings and a second set of circumferentially disposed tabs extending from the mounting portion with ends cast into the other of the pair of friction rings. 
   
   
       21 . The wheel hub according to  claim 18 , wherein each tab has an “S” or a “Z” shaped cross section. 
   
   
       22 . The wheel hub according to  claim 20 , wherein each tab has an “S” or a “Z” shaped cross section. 
   
   
       23 . A rotor for a disc brake comprising:
 at least one friction ring including a friction surface adapted for contact with a brake pad during braking;   an annular mounting portion by which the rotor is attachable to a hub; and   joining means for joining the friction ring and the mounting portion permitting radial expansion and contraction of the friction ring relative to the mounting portion upon heating and cooling of the rotor.   
   
   
       24 . The rotor according to  claim 23 , wherein the mounting portion is a steel mounting portion, and wherein the joining means includes circumferentially disposed steel tabs extending from the mounting portion with ends cast into the friction ring. 
   
   
       25 . The rotor according to  claim 23 , wherein the friction ring is one of a pair of friction rings, and wherein the joining means includes elements interconnecting the friction rings as well as slots, formed in a steel mounting ring including said annular mounting portion, within which said elements are slidable. 
   
   
       26 . The rotor according to  claim 23 , wherein the friction ring, the mounting portion, and the joining means are integrally formed of cast iron. 
   
   
       27 . The rotor according to  claim 26 , wherein the joining means is defined by a deformable portion of the rotor having at least one recurved section. 
   
   
       28 . The rotor according to  claim 23 , wherein the friction ring is formed of cast iron and both the annular mounting portion and the joining means are formed of steel. 
   
   
       29 . The rotor according to  claim 28 , wherein the joining means is pre-stressed in a direction to reduce stress as the friction ring expands during heating. 
   
   
       30 . The rotor according to  claim 29 , wherein the joining means is pre-stressed in a radially inward direction before the friction ring is cast. 
   
   
       31 . The rotor according to  claim 23 , wherein the joining means includes a bend facilitating radial expansion and contraction of the friction rings.